Robust binder bonded grinding wheel

ABSTRACT

An abrasive tool includes a matrix material and an abrasive grain contained within the matrix material. The matrix material includes a binder and an block copolymer. The block copolymer including a binder miscible block and a binder immiscible block. The binder immiscible block of the block copolymer can form toughening domains within the matrix material. A method of forming an abrasive tool includes blending a binder powder, an block copolymer powder, and an abrasive grain to form a blended powder, shaping the blended powder, and curing the blended powder.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present application claims priority from U.S. Provisional PatentApplication No. 61/427,577, filed Dec. 28, 2010, entitled “ROBUST BINDERBONDED GRINDING WHEEL,” naming inventor Lingyu Li, which application isincorporated by reference herein in its entirety.

BACKGROUND

1. Field of the Disclosure

The following is directed to an abrasive tool, and particularly directedto a robust binder bonded grinding wheel.

2. Description of the Related Art

Abrasive wheels are typically used for cutting, abrading, and shaping ofvarious materials, such as stone, metal, glass, plastics, among othermaterials. Generally, the abrasive wheels can have various phases ofmaterials including abrasive grains, a bonding agent, and some porosity.Depending upon the intended application, the abrasive wheel can havevarious designs and configurations. For example, for applicationsdirected to the finishing and cutting of metals, some abrasive wheelsare fashioned such that they have a particularly thin profile forefficient cutting.

However, given the application of such wheels, the abrasive articles aresubject to fatigue and failure. In fact, the wheels may have a limitedtime of use of less than a day depending upon the frequency of use.Accordingly, the industry continues to demand abrasive wheels capable ofimproved performance.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure may be better understood, and its numerousfeatures and advantages made apparent to those skilled in the art byreferencing the accompanying drawings.

FIG. 1 includes an illustration of an abrasive tool in accordance withan embodiment.

FIG. 2 includes an illustration of diblock copolymer in accordance withan embodiment.

FIG. 3 includes an illustration of triblock copolymer in accordance withan embodiment.

FIG. 4 includes a micrograph illustrating the microstructure formed by ablock copolymer and a resin in accordance with an embodiment.

FIG. 5 includes a bar graph illustrating the burst speed of a standardabrasive article and a block copolymer abrasive article in accordancewith an embodiment.

The use of the same reference symbols in different drawings indicatessimilar or identical items.

DETAILED DESCRIPTION

The following is directed to bonded abrasive tools utilizing abrasivegrains contained within a matrix material for cutting, abrading, andfinishing of work pieces. The matrix material can include a binder andan amphiphilic block copolymer including a binder miscible block and abinder immiscible block. Certain embodiments herein are directed toabrasive wheels that are particularly suited for cutting and/or shapingmetal.

FIG. 1 includes an illustration of an abrasive tool in accordance withan embodiment. Notably, the abrasive tool 100 includes a body 101 havinga generally circular shape as viewed in two dimensions. It will beappreciated, that in three-dimensions the tool has a certain thicknesssuch that the body 101 has a disk-like or a cylindrical shape. In anembodiment, the body can have an average thickness of at least about 0.1cm and not greater than about 3 cm. For example, the average thicknesscan be within a range between about 0.5 cm and about 2 cm. Asillustrated, the body can have an outer diameter 103 extending throughthe center of the tool. The outer diameter 103 can be within a range of15 cm to about 100 cm. In a particular embodiment, the outer diametercan be at least about 45 cm.

As further illustrated, the abrasive tool 100 can include a centralopening 105 defined by an inner circular surface 102 about the center ofthe body 101. The central opening 105 can extend through the entirethickness of the body 101 such that the abrasive tool 100 can be mountedon a spindle or other machine for rotation of the abrasive tool 100during operation.

In an embodiment, the body can include a tapered region extendingcircumferentially around a portion of a periphery of the body. Thetapered region can extend through the entire circumference of the body.Additionally, the tapered region extends radially from a flat region ofthe body. In a particular embodiment, the tapered region of the bodycomprises an average thickness that is greater than an average thicknessof the flat region of the body.

In an embodiment, the body of the abrasive tool can include an abrasivegrain contained within a matrix material. In an example, the abrasivegrain can include superabrasive material, such as diamond, cubic boronnitride, and a combination thereof. In another example, the abrasivegrains comprise a material selected from the group of materialsconsisting of oxides, carbides, borides, nitrides, and a combinationthereof. In a particular embodiment, the abrasive grains can consistessentially of oxides. The oxide material can include alumina, zirconia,silica, or any combination thereof. Additionally, the abrasive grainscomprise a Vickers hardness of at least about 5 GPa. In an embodiment,the abrasive grain can be present in an amount from about 50 wt % toabout 80 wt % of the abrasive tool.

The matrix material can include a binder, such as a phenolic resin or anepoxy resin, and an amphiphilic block copolymer. In an example, thematrix material can include from about 70 wt % to about 95 wt % binderand from about 5 wt % to about 30 wt % amphiphilic block copolymer.

The amphiphilic block copolymer can include at least two blocks and caninclude blocks comprising poly(methyl methacrylate), polystyrene,polybutadiene, or any combination thereof. In an example, theamphiphilic block copolymer can be a diblock copolymer or a triblockcopolymer.

FIG. 2 includes an illustration of an exemplary diblock copolymer 200.The diblock copolymer 200 can include blocks 202 and 204. Additionally,the diblock copolymer can include repeating units consisting of blocks202 and 204, such that block 204 is followed by block 202 and block 202is followed by block 204. The block 202 can comprise a different polymerfrom the block 204, and as such, the properties of block 202 can bedifferent from the properties of block 204.

FIG. 3 includes an illustration of an exemplary triblock copolymer 300.The triblock copolymer 300 can include blocks 302, 304, and 306.Additionally, the diblock copolymer can include repeating unitsconsisting of blocks 302, 304, and 306, such that block 306 is followedby another block 302. Block 304 can comprise a different polymer fromblock 302 and from block 306. Additionally, block 302 can comprise adifferent polymer from block 306, such that each of block 302, 304, and306 comprises a different polymer form the other blocks. In an alternateembodiment, block 302 and 306 can comprise a substantially similarpolymer.

Further, the amphiphilic block copolymer can include a binder miscibleblock and a binder immiscible block. A binder miscible block can be apolymer block that is soluble in the resin such that the miscible blockand the resin form a single phase of the matrix. In contrast, a binderimmiscible block can substantially insoluble in the resin and can form aseparate phase within the matrix. In an example, a polystyrene block ismiscible in phenolic resin but immiscible in epoxy. In contrast, apoly(methyl methacrylate) block is immiscible in phenolic resin butmiscible in epoxy. As such, a copolymer consisting of a polystyreneblock and a poly(methyl methacrylate) block can be an amphiphilic blockcopolymer for both phenolic resins and epoxy resins.

The alternating properties of the amphiphilic block copolymer can resultin the self-assembly of a particular morphology when combined with theresin. An example of the morphology is depicted in the micrograph ofFIG. 4. The micrograph of FIG. 4 is a micrograph of a portion of amatrix material that can be used to form an abrasive tool, e.g., agrinding wheel.

In a particular aspect, the matrix material can include a binder 402 anda block copolymer within the binder. The block copolymer can include atleast a first portion and second portion, i.e., the block copolymer caninclude a diblock copolymer, a triblock copolymer, a tetrablockcopolymer, or some other multi-block copolymer.

As indicated in FIG. 4, the matrix material can include a plurality oftoughening domains 404 dispersed within the matrix material. Each of thetoughening domains can include the first portion of the block copolymerand can exist as a first phase within the matrix material. Further, anabrasive grain can be dispersed within the matrix material.

In a particular aspect, the second portion of the block copolymer andthe binder form a single phase different from the phase of thetoughening domains. Moreover, the second phase formed from the secondportion of the block copolymer and the binder can at least partiallysurround the first phase formed included in the toughening domains. Inanother aspect, the first portion of the block copolymer includes abinder immiscible portion and the second portion of the block copolymercomprises a binder miscible portion. The immiscible/miscible quality ofthe block copolymer can lead to the formation of the first phase and thesecond phase within the matrix material. Further, theimmiscible/miscible quality of the block copolymer can lead to differentmorphology of the toughening domain structures, e.g., spherical domainstructures, vesicular domain structures, cylindrical domain structures,etc.

As depicted in FIG. 4, each toughening domain can be generallyellipsoidal in cross-section. Further, each toughing domain can begenerally circular in cross-section. In one aspect, the tougheningdomains include an average diameter of at least about 0.1 μm. In anotheraspect, the toughening domains can include an average diameter of atleast about 0.2 μm, at least about 0.3 μm, at least about 0.4 μm, atleast about 0.5 μm, at least about 1.0 μm, at least about 2.5 μm, or atleast about 5.0 μm. Further, the toughening domains can include anaverage diameter that is not greater than about 25.0 μm, not greaterthan about 20.0 μm, not greater than about 15.0 μm, or not greater thanabout 10.0 μm. The average diameter can be within a range between andincluding any of the minimum and maximum average diameters describedabove.

For example, the toughening domains can include an average diameterbetween and including 0.1 μm and 25.0 μm. Also, the toughening domainscan include an average diameter between and including 0.1 μm and 20.0μm, between and including 0.1 μm and 15.0 μm, between and including 0.1μm and 10.0 μm, between and including 0.1 μm and 5.0 μm, between andincluding 0.1 μm and 2.5 μm, or between and including 0.1 μm and 0.5 μm.

In still another aspect, the toughening domains can include a tougheningdomain hardness that is less than a binder hardness. Specifically, thetoughening domain hardness can be less than about 90% of the binderhardness as given by the equation [H_(TD)/H_(B)]×100%, wherein H_(TD) isthe toughening domain hardness and H_(B) is the binder hardness.Moreover, the toughening domain hardness can be less than about 85% ofthe binder hardness, less than about 80% of the binder hardness, lessthan about 75% of the binder hardness, or less than about 70%. Inanother aspect, the toughening domain hardness can be greater than about60% of the binder hardness. The toughening domain hardness can be withina range between and including any of the minimum and maximum percentagevalues described above.

In another aspect, the toughening domains can be substantially uniformlydispersed throughout an entire volume of the matrix material. In otherwords, the majority of the toughening domains can be spaced apart fromeach other. Specifically, at least about 70% of the toughening domainscan be spaced apart from each other. Moreover, at least about 75%, atleast about 80%, at least about 85%, at least about 90%, at least about95%, or at least about 99% of the toughening domains can be spaced apartfrom each other. In another aspect, essentially all of the tougheningdomains can be spaced apart from each other.

In still another aspect, the matrix material can include a tougheningdomain concentration of at least about 1 toughening domains per 1 μm² asviewed in cross-section at a magnification of about 25000×. Further, thetoughening domain concentration can be at least about 2 tougheningdomains per 1 μm², at least about 3 toughening domains per 1 μm², atleast about 4 toughening domains per 1 μm², or at least about 5toughening domains per 1 μm². The toughening domain concentration maynot be greater than about 10 toughening domains per 1 μm². Thetoughening domain concentration can be within a range between andincluding any of the minimum and maximum concentration values describedabove.

For example, the matrix material can include a toughening domainconcentration between and include 1 toughening domains per 1 μm² and 10toughening domains per 1 μm². Further, the toughening domainconcentration can be between and include 1 toughening domains per 1 μm²and 5 toughening domains per 1 μm².

The matrix material can include at least about 0.5 wt % of blockcopolymer for a total weight of the matrix material. Moreover, thematrix material can include at least about 1% of the block copolymer,about 2 wt % of block copolymer, at least about 3 wt % of blockcopolymer, at least about 4 wt % of block copolymer, or at least about 5wt % of block copolymer for the total weight of the matrix material.Further, the matrix material can include not more than about 10 wt % ofblock copolymer for the total weight of the matrix material. The amountof block copolymer can be within a range between and including any ofthe minimum and maximum wt % amounts described above.

For example, the matrix material can include between and including about0.5 wt % block copolymer and about 10 wt % block copolymer. The matrixmaterial can include between and including about 0.5 wt % blockcopolymer and about 8 wt % block copolymer or between and includingabout 0.5 wt % block copolymer and about 5 wt % block copolymer.

The block copolymer can include a polydispersity index less than about1.4. Further, the polydispersity index can be less than about 1.3 or1.2. However, the polydispersity index may be greater than about 1.1. Inanother aspect, the polydispersity index can be between and includingabout 1.1 and about 1.4. Also, polydispersity index can be between andincluding about 1.1 and about 1.3. As the polydispersity indexapproaches 1, a length of each chain within the block copolymer will besubstantially the same.

In another aspect, an abrasive tool constructed using the matrixmaterial illustrated in FIG. 4 can include a burst speed of at leastabout 6800 RPM. Moreover, such an abrasive tool can include a burstspeed of at least about 6850 RPM, at least about 6900 RPM, at leastabout 6950 RPM, at least about 7000 RPM, or at least about 7050 RPM. Ina particular aspect, the burst speed may not be greater than about 7100RPM.

In yet another aspect, the block copolymer can include a molar mass ofat least about 3000 g/mol. Specifically, the molar mass can be at leastabout 3100 g/mol, at least about 3200 g/mol, at least about 3300 g/mol,at least about 3400 g/mol, or at least about 3500 g/mol. In anotheraspect, the molar mass can be at least about 10000 g/mol, at least about15000 g/mol, at least about 20000 g/mol, at least about 25000 g/mol, atleast about 30000 g/mol, at least about 35000 g/mol, at least about40000 g/mol, at least about 45000 g/mol, or at least about 50000 g/mol.

The toughening domains can act as dampeners during use a grinding wheelin which the toughening domains are incorporated. In other words, thetoughening domains can absorb energy during use of a grinding wheel inwhich the toughening domains are incorporated. The dampening or energyabsorption can be attributed to the differences in hardness between thetoughening domains and the binder.

Turning to a method of making the bonded abrasive tool, a binder powder,an amphiphilic block copolymer powder, and an abrasive grain to form ablended powder.

The binder powder can include a solid phenolic resin or a solid epoxyresin. The amphiphilic block copolymer powder, can include a solidamphiphilic block copolymer. The solid amphiphilic block copolymer caninclude a binder miscible block and a binder immiscible block. In anembodiment, the blended powder can include from about 15 wt % to about50 wt % binder, from about 1 wt % to about 15 wt % amphiphilic blockcopolymer, and from about 50 wt % to about 80 wt % abrasive grain.

The blended powder can be shaped into the form of a bonded abrasive. Inan embodiment, a mold cavity can be filled with the blended powder, andthe blended powder can be compressed within the mold. For example, theblended powder can be compressed by cold pressing, or heat can be addedto the powder during pressing, such as by hot pressing.

After shaping, the matrix material shaped powder can be cured to form anabrasive tool. For example, the matrix material can be cured by heatingthe blended powder to a curing temperature, such as at least about 200°C. In an embodiment, the matrix material can be substantially curedwhile remaining within the mold cavity. In another embodiment, thematrix material can be partially cured to a point sufficient to maintainthe shape of the abrasive tool when removed from the cavity. Theabrasive tool can be subjected to additional curing to substantiallycure the matrix material after being removed from the mold cavity.

The abrasive tools described herein can have certain features that makethe abrasive tool suitable for improved grinding and/or cuttingapplications. Notably, the fracture toughness of the bonded abrasivetool is improved. For example, the fracture toughness can be determinedby measuring the force required to cause a crack to form in the abrasivetool, designated as the G₁C, or by measuring the specific work off force(SpWOF) which corresponds to the force required to break a piece off thebonded abrasive tool. The abrasive articles of embodiments hereindemonstrate an improved percent increase G₁C and percent increase SpWOFas compared to conventional abrasive articles. Notably, for comparativepurposes, the conventional abrasive articles included abrasives of thesame design having the matrix material comprising resin without theaddition of the amphiphilic block copolymer. According to empiricalevidence, the abrasive tool can have a percent increase G₁C of at leastabout 20% over a similar abrasive tool without the amphiphilic blockcopolymer. The percent increase is based on the equation((G_(N)−G_(C))/G_(C)×100%) wherein G_(N) represents the G₁C of anabrasive tool including the amphiphilic block copolymer and G_(C)represents the G₁C of the abrasive tool without the amphiphilic blockcopolymer. In other embodiments, the percent increase G₁C can be atleast about 30%, such as at least about 40%, such as at least about 50%,even at least about 60%. In an embodiment, the percent increase G₁C canbe not greater than about 500%.

Additionally, empirical evidence also demonstrates that the abrasivetool can have a percent increase SpWOF of at least about 10% over asimilar abrasive tool without the amphiphilic block copolymer. Further,the percent increase SpWOF can be at least about 15%, such as at leastabout 20%. The percent increase is based on the equation((S_(N)−S_(C))/S_(C)×100%) wherein S_(N) represents the SpWOF of anabrasive tool having the amphiphilic block copolymer and S_(C)represents the SpWOF of the abrasive tool without the amphiphilic blockcopolymer. In other embodiments, the percent increase SpWOF can be notgreater than about 500%.

Liquid amphiphilic block copolymers, such as described in US Publication2009/0082486 A1, have been used to toughen epoxy resins used inapplications such as laminating. These applications have relied upon aamphiphilic block copolymer comprising poly(ethylene oxide) (PEO) andpoly(butylene oxide) (PBO). However, the use of a liquid resin systemcan cause problems with the production of bonded abrasives articles,such as the partial settling of the abrasive grains within the liquid.This may lead to a non-uniform distribution of abrasive grains anduneven grinding performance. The use of a solid amphiphilic blockcopolymer powder provides a particular advantage for the formation ofbonded abrasive articles.

Further, in certain embodiments, the amount of block copolymer that canbe used to increase the strength, or toughness, of a binder used in agrinding wheel application can be such a small amount when compared tothe binder material that it would be extremely difficult to getsubstantially uniform dispersal when mixing a liquid form of such acopolymer with a binder powder. However, mixing a powdered form of sucha block copolymer can allow for the uniform dispersal of the blockcopolymer within the binder powder prior to formation of an abrasivearticle from the block copolymer/binder powder mixture.

EXAMPLES

Several types of abrasive articles are formed and tested to comparecertain performance parameters including the critical energy releaserate (G1C) and specific work-off force (SpWOF). The G1C is a measure ofthe force necessary to cause the test abrasive article to crack, and theSpWOF is a measure of the force necessary to cause a portion of the testabrasive article to break off.

Comparative Sample 1 is a phenolic resin based formulation prepared bypressing a phenolic resin powder into a mold and heating it to atemperature of 200° C. for 1 hour.

Sample 1 is prepared as Comparative Sample 1 with the addition of anamphiphilic block copolymer powder. The phenolic resin and theamphiphilic block copolymer are blended at a ratio of 90 wt % resin to10 wt % copolymer to form a substantially homogeneous powder blend. Thepowder blend is pressed into a mold and heated to a temperature of 200°C. for 1 hour. Table 1 shows the results of the G1C and SpWOF tests.

TABLE 1 G1C % increase G₁C SpWOF % increase SpWOF CS1 1304 1635 Sample 11890 45% 2446 50%

Comparative Sample 2 is a phenolic resin based formulation prepared bypressing a phenolic resin powder into a mold and heating it to atemperature of 200° C. for 1 hour.

Sample 2 is prepared as Comparative Sample 2 with the addition of anamphiphilic block copolymer powder. The phenolic resin and theamphiphilic block copolymer are blended at a ratio of 90 wt % resin to10 wt % copolymer to form a substantially homogeneous powder blend. Thepowder blend is pressed into a mold and heated to a temperature of 200°C. for 1 hour. Table 2 shows the results of the G₁C and SpWOF tests.

TABLE 2 G1C % increase G₁C SpWOF % increase SpWOF CS2 500 765 Sample 2620 40% 900 15%

Comparative Sample 3 is a phenolic resin based formulation prepared bypressing a phenolic resin powder into a mold and heating it to atemperature of 200° C. for 1 hour.

Sample 3 is prepared as Comparative Sample 2 with the addition of anamphiphilic block copolymer powder. The phenolic resin and theamphiphilic block copolymer are blended at a ratio of 90 wt % resin to10 wt % copolymer to form a substantially homogeneous powder blend. Thepowder blend is pressed into a mold and heated to a temperature of 200°C. for 1 hour. Table 3 shows the results of the G₁C and SpWOF tests.

TABLE 3 G1C % increase G₁C SpWOF % increase SpWOF CS3 160 720 Sample 3260 63% 790 10%

As can be seen by the data provided in Tables 1 through 2, the additionof particular amphiphilic block copolymer to the resin of bondedabrasive articles can improve the toughness of the bonded abrasivearticles. Specifically, both the force need to crack the matrix materialand the force needed to break the matrix material are increased of thecomparable formulations without the amphiphilic block copolymer.

In another example, a standard abrasive article is prepared using theformulation detailed in Table 4, below. Table 5 lists the ingredientsfor the standard bond referred to in Table 4. A block copolymer (BCP)abrasive article is also prepared using the same formulation as detailedin Table 4. However, the BCP abrasive article includes the addition of ablock copolymer, as described herein, to the standard bond material. Theblock copolymer includes a binder immiscible block and a binder miscibleblock. Further, the block copolymer includes a PMMA block copolymer.Specifically, the block copolymer includespolystyrene-b-polybutadiene-b-syndiotactic poly methyl methacrylate.

Specifically, the block copolymer is blended with the standard bond at aratio of 1:99 (block copolymer to standard bond). Moreover, the blockcopolymer is in a solid, powder form to facilitate thorough mixing andsubstantially uniform dispersion, as described herein. Dispersion isdetermined by taking various micrographs of the completed BCP abrasivearticle and determining the associated dispersion of the tougheningdomains formed by the immiscible portion of the block copolymer.

TABLE 4 Grinding Wheel Formulation. Vol. Type Vol. % Fract. Wt. % Abr.Alumina- 25.00 1.145 69.58 Zirconia Bond standard 42.10 0.922 29.00 Furf3.90 0.045 1.42

TABLE 5 Standard bond. weight % 32% Phenolic Resin 37% Iron Pyrites 21%Potassium Sulfate  2% Alcohol, Tridecyl  8% Lime

Once the mixture for each wheel is blended, the powder blend is pressedinto a mold and heated to a temperature of 200° C. for 1 hour. After theabrasive articles are made, each abrasive article is placed in a bursttesting apparatus. Each abrasive article is freely spun, or rotated,until each wheel fails catastrophically, i.e., until it bursts. Thespeed at which the abrasive article fails is recorded as the burstspeed.

FIG. 5 shows the results of the burst testing as a simple bar graph. Thestandard abrasive article provides a burst speed of approximately 6800RPM. The BCP abrasive article constructed using the block copolymer asdescribed herein provides a burst speed of approximately 7100 RPM.Accordingly, the BCP abrasive article constructed using the blockcopolymer provides a burst speed that is approximately 4.4% higher thanthe burst speed of the standard abrasive articles as given by theformula: [BS_(BCP)BS_(ST)]/BS_(ST)×100%, wherein BS_(BCP) is the burstspeed of the BCP abrasive article and BS_(ST) is the burst speed of thestandard abrasive article.

The above-disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments, which fall withinthe true scope of the present invention. Thus, to the maximum extentallowed by law, the scope of the present invention is to be determinedby the broadest permissible interpretation of the following claims andtheir equivalents, and shall not be restricted or limited by theforegoing detailed description.

The Abstract of the Disclosure is provided to comply with Patent Law andis submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. In addition, inthe foregoing Detailed Description of the Drawings, various features maybe grouped together or described in a single embodiment for the purposeof streamlining the disclosure. This disclosure is not to be interpretedas reflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter may be directed toless than all features of any of the disclosed embodiments. Thus, thefollowing claims are incorporated into the Detailed Description of theDrawings, with each claim standing on its own as defining separatelyclaimed subject matter.

1.-82. (canceled)
 83. An abrasive tool comprising: a matrix materialcomprising a binder and a block copolymer, the block copolymer includinga binder miscible block and a binder immiscible block, wherein thebinder immiscible block forms a plurality of toughening domainsdispersed within the matrix material; and an abrasive grain containedwithin the matrix material.
 84. The abrasive tool of claim 83, whereinthe binder is a phenolic resin, an epoxy resin, or any combinationthereof
 85. The abrasive tool of claim 83, wherein the block copolymerincludes poly(methyl methacrylate), polystyrene, polybutadiene, or anycombination thereof
 86. The abrasive tool of claim 83, wherein theabrasive tool has a percent increase G1C of at least about 20% over asimilar abrasive tool without the block copolymer, wherein the percentincrease is based on the equation ((GN−GC)/GC×100%) wherein GNrepresents the G1C of an abrasive tool having the block copolymer and GCrepresents the G1C of the abrasive tool without the block copolymer. 87.The abrasive tool of claim 83, wherein the abrasive tool has a percentincrease SpWOF of at least about 10% over a similar abrasive toolwithout the block copolymer, wherein the percent increase is based onthe equation ((SN−SC)/SC×100%) wherein SN represents the SpWOF of anabrasive tool having the block copolymer and SC represents the SpWOF ofthe abrasive tool without the block copolymer.
 88. The abrasive tool ofclaim 83, wherein the matrix material includes from about 70 wt % toabout 95 wt % binder.
 89. The abrasive tool of claim 83, wherein thematrix material includes from about 5 wt % to about 30 wt % blockcopolymer.
 90. The abrasive tool of claim 83, wherein the abrasive grainis present in an amount from about 50 wt % to about 80 wt % of theabrasive tool.
 91. The abrasive tool of claim 83, wherein the bodycomprises an outer diameter within a range of about 15 cm to about 100cm.
 92. The abrasive tool of claim 83, wherein the body comprises anaverage thickness of not greater than about 3 cm.
 93. The abrasive toolof claim 83, wherein the matrix material comprises a plurality oftoughening domains having a first phase formed from the binderimmiscible block and wherein each of the toughening domains is at leastpartially surrounded by a second phase formed from the binder miscibleblock and the binder
 94. A method comprising: blending a binder powder,a block copolymer powder, and an abrasive grain to form a blendedpowder, the block copolymer including a binder miscible block and abinder immiscible block; shaping the blended powder; and curing theblended powder to form an abrasive tool.
 95. The method of claim 94,wherein the blended powder includes from about 15 wt % to about 50 wt %binder, about 1 wt % to about 15 wt % block copolymer; and about 50 wt %to about 80 wt % abrasive grain.
 96. An abrasive tool comprising: amatrix material comprising: a binder; a block copolymer within thebinder, the block copolymer having at least a first portion and a secondportion; a plurality of toughening domains dispersed within a binder,wherein each of the plurality of toughening domains comprise the firstportion of the block copolymer; and an abrasive grain within the matrixmaterial.
 97. The abrasive tool of claim 96, wherein the tougheningdomains include an average diameter between and including 0.1 μm and25.0 μm.
 98. The abrasive tool of claim 96, wherein the tougheningdomain hardness is between and includes about 60% of the binder hardnessand about 90% of the binder hardness.
 99. The abrasive tool of claim 96,wherein the matrix material includes a toughening domain concentrationbetween and including 1 toughening domain per 1μm² and 10 tougheningdomains per 1μm².
 100. The abrasive tool of claim 96, wherein the blockcopolymer comprises a polydispersity index between and including about1.1 and about 1.4.
 101. The abrasive tool of claim 96, furthercomprising a burst speed of at least about 6800 RPM.
 102. The abrasivetool of claim 96, wherein the block copolymer comprises a molar mass ofat least about 3000 g/mol.